Infusible material capsule for brewing a beverage

ABSTRACT

A sealed capsule for use in apparatus including a capsule receiving station and a water delivery system for brewing a hot beverage in which a hot liquid under pressure infuses a material. A capsule base has a concave bottom floor with angularly spaced structural ribs that form channels for directing brewed beverage to a sharpened spout. A collar surrounds the dispensing spout. A foil attaches to the collar to overlie the spout. A filter lies on the structural ribs. Infusible material lies on the filter. A water distribution plate overlies the infusible material. A cover closes the base unit and includes a water inlet. As the capsule seats in the capsule receiving station, the foil seal is forced over the sharpened spout to rupture and enable brewed beverage to be dispersed. A probe of the water delivery system also penetrates the cover to direct water into the capsule without contacting the infusible material or the brewed beverage.

CROSS REFERENCE TO RELATED APPLICATION

U.S. patent application Ser. No. 11/772,416 for a Hot Beverage BrewingApparatus filed on the same day as this application, assigned to thesame assignee as the present invention and incorporated by referenceherein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to the brewing of beverages. Morespecifically this invention relates to the construction and manufactureof sealed capsules containing infusible material, such as ground coffee,for brewing beverages.

2. Description of Related Art

For many years preparing a beverage, such as coffee, has involvedbrewing multiple servings in a pot or other container using loose coffeegrounds. In some apparatus, the coffee grounds mix with hot water andare then removed from the brewed beverage as, for example, in theso-called “French press” coffee maker. Other apparatus directs hotliquid at low pressure through an open or closed basket containing theloosely ground coffee over a filter, such as a paper filter cone.

The procedures and apparatus for brewing beverages, particularly coffee,have undergone many transformations in recent years spurred by differentmarket requirements. A convenience requirement led to prepackagedpackets of ground coffee as a substitute for manually measuring coffeefrom bulk packages of loose, ground coffee, as in conventional dripcoffee makers. A prepackaged packet comprises a permeable filter paperpouch with a pre-measured portion of loose ground coffee. An imperviouspackage stores the packet to maintain freshness. A packet is removedfrom its package and placed in a basket or like receptacle. Then hotwater at atmospheric pressure flows through the packet and its contentsfor extracting flavor and aroma from the ground coffee.

Another market requirement has evolved as many users have indicated apreference to brew individual beverage servings. This preference forsingle-serve coffee brewing apparatus, especially for home use, led tothe development of pre-packaged disposable coffee capsules, orcartridges, and related brewing apparatus. For example, U.S. Pat. No.4,921,712 to Malmquist discloses a disposable cartridge for use in anautomatic drip-type beverage brewing machine. The cartridge comprises afirst cup which has an open first end and a substantially closed secondend penetrated by at least one port. A filter member contains groundcoffee and nests within the first cup. A second cup has an open bottomend and a substantially closed top end and overlies the first cup. Theclosed end of the second cup has a plurality of holes and forms ashallow receptacle. A user removes a sealing foil from the second cupand places the cartridge on ledges in a brewing apparatus spaced from awater delivery spout. The apparatus delivers hot water at low pressureand at a controlled rate onto the top of the cartridge. There is norequirement for sealing between the apparatus and the cartridge so longas water does not overflow the shallow receptacle.

U.S. Pat. No. 7,097,074 (2006) and U.S. Patent Application No.2004/01997444 both to Haliday et al. and U.S. Pat. No. 6,681,960 (2004)to Garman disclose another low-pressure beverage preparation system. Inthis system a brewing chamber receives a cartridge.

Minimizing the brewing time became another market requirement. It wasdetermined early on that the extraction time or “brewing cycle” of suchbrewing apparatus could be shortened significantly if coffee beans wereground more finely than those used in such drip-type brewing apparatus.Finer grinding exposes a larger surface area to the water. However, thecoffee grounds have a higher packing fraction and volumetric density.This increases hydraulic resistance to the flow of water through thecartridge and the grounds therein. Therefore, the water has to bedelivered in a closed brewing chamber under an elevated pressure to beable to flow through the coffee in a short period of time.

This led to a development of sealed brewing chambers formed by membersthat are integral to the brewing apparatus. For example, U.S. Pat. No.4,389,925 (1983) to Paina describes a beverage extracting and dispensingmachine for use with flattened round cartridges. A cartridge contains abrewable product, such as ground coffee, and has permeable upper andlower walls traversing a substantially cylindrical side wall. In thisreference a pressure plate coacts with the cartridge to provide sealing.

However, brewing under pressure creates a problem because seals about abrewing chamber are subject to leaking. One approach has been to designbrewing chambers with intricate seals. However, as the seals become moreimportant to the integrity of the process, the placement of capsulesbecomes more critical to prevent water from bypassing the capsule and toavoid interference between portions of the capsule and the brewingchamber that could cause the seal to leak.

Ease of cleaning has become yet another market requirement. Cleaningsuch brewing apparatus can be complicated and can introduce complexitiesin the design and manufacture of such apparatus. A sealed brewingchamber is a part of the brewing apparatus and its surfaces contact thebrewed beverage. Thus, after use, it is necessary to clean the interiorsurfaces of the brewing chamber. Preferably such surfaces should be oncomponents of the apparatus that are easily removed for cleaning.

Use of such brewing apparatus in a non-residential or non-homeenvironment, such as in a hotel room or other commercial environment,imposes still other market requirements. Criteria for this commercialmarket are quite different. In a hotel environment, for example, in-roomcoffee apparatus must be inexpensive, be operated reliably with minimaloperating costs and be easy to use. Moreover, and most importantly, suchbrewers must minimize the efforts of room attendants to clean andmaintain the brewing apparatus, to dispose of used coffee grounds and toreplenish coffee supplies in the room. In many hotels, in-room coffeeapparatus includes a water heater, cups and prepackaged, pre-measuredsealed packets of instant coffee. Other hotels have begun to useconventional coffee brewing machines that use capsules or cartridges tobrew the coffee.

The advent of a desire to use a single apparatus to brew differentserving sizes imposed another market requirement. When single-servecoffee brewing apparatus was introduced, there was a de facto standardserving size of about 175 ml (6 oz.). Over time, however, differentsingle-serving sizes have become popular, requiring pre-measuredpackages of coffee in different sizes. One approach is to supply eachpre-measured quantity in a cartridge of a unique size and capacity. Arequirement for capsules of different sizes requires the capsulemanufacturer to inventory parts for each size and adjust variousparameters of the manufacturing process to accommodate such sizes.Moreover, differently sized capsules can complicate the construction ofbrewing apparatus to allow the apparatus to accommodate capsules ofdifferent sizes.

All of these market requirements have led to proposals for a widevariety of capsule structures and related apparatus. For example, U.S.Pat. Nos. 5,197,374, 5,242,702 and 5,897,899 (199) to Fond disclosedevices for extracting coffee contained in a cartridge and a number ofvariations on sealed cartridges. The cartridge has a cup and cover toform a sealed container for an infusible material. When installed in abrewing apparatus, a water injector pierces either the cover or the capto apply water under pressure to be discharged through a flow grill orlike portion of the capsule.

In U.S. Pat. No. 4,846,052 to Favre et al., a device extracts material,such as coffee, from an infusible material contained in a sealedcartridge by puncturing one end of a cartridge with a sharpened waterdelivery tube and by perforating the other end of the cartridge todispose the brewed beverage into a dispensing passage.

U.S. Pat. No. 5,794,519 (1998) to Fischer discloses a brewing headincluding lower and upper parts hingably connected together. A pluralityof hollow needles project from the upper part into a brewing cavity fordelivering water to the interior of a coffee brewing capsule. The lowerpart has projections intended to puncture the lower side of the coffeecapsule. An ejector device within the upper part ejects a used coffeecapsule.

U.S. Pat. Nos. 6,499,388 (2002) and 6,536,332 (2003) to Schmed discloseperforator members located in a brew chamber perforating one end of acoffee cartridge for extracting brew from the cartridge. The brewchamber forms a sealed receptacle during brewing.

U.S. Pat. No. 6,880,454 (2005) to Kollep discloses perforator memberslocated in a brew chamber. The perforator members pierce a capsule todeliver water for brewing coffee. U.S. Pat. No. 6,966,251 (2005) toYoakim discloses an alternate embodiment in which perforator memberslocated in the brew chamber perforate a coffee capsule.

U.S. Patent Application No. 2005/0172822 to Macchi et al. discloses acartridge for coffee. The cartridge comprises a container for a solubleproduct, a lid placed on top of the container and a filter positionedinside the container. A bottom wall of the container comprises a thin,weakened central portion and a breakable portion. The brewing apparatusreceives the cartridge in a sealed chamber. After brewing, the pressurebreaks the bottom to allow the beverage to be dispersed.

U.S. Pat. No. 6,607,762 (2003) to Lazaris et al. discloses a filtercartridge where a permeable beverage filter element divides the interiorof the container into first and second chambers. Ribs support thepermeable filter within the container. The first chamber contains thebeverage medium; the second collects the brewed beverage for dispensing.Infusion and exit probes penetrate a lid to direct water into and brewedbeverage from the first and second chambers, respectively.

U.S. Pat. No. 6,832,542 to Hu et al. discloses a capsule for preparationof beverages by directing hot water under pressure to the capsule. Asection of the capsule is adapted to deform inwardly upon action of theinternal water pressure. The capsule is in a sealed chamber duringbrewing.

U.S. Patent Application Nos. 2003/0172813, 2005/0150390 and 2005/0150391to Schifferle disclose cartridges containing a single serving ofsubstance extractable by means of water for preparing a beverage. Fluiddirector members positioned ahead of and behind the substance distributethe water. A gas-tight foil covers the cartridge. Specifically, U.S.Patent Application No. 2005/0150391 discloses a coffee maker for brewingpowder coffee contained in a cartridge. The bottom of the cartridge isprovided with an aperture. A foil covers the inside of the bottom of thecartridge.

Experience with prior art capsules and brewing apparatus have led to anew set of required market features for apparatus that can be used inboth residential and commercial environments. Specifically these marketsdemand a capsule containing infusible material such as coffee, which issimple to use and inexpensive to manufacture and which preserves thefreshness of the infusible material. The capsules must enable infusiblematerial to be brewed under pressure in the capsule. The capsules mustbe tamper-proof so an individual user can be assured that others havenot touched the capsule contents. When such capsules are used in abrewing apparatus, the brewing capsules must be sufficiently rigid forbeing stored in and dispensed from vending machines or other dispensersfor preventing damage during brewing. They must also be readilydisposable. Further, the capsule structure must enable the constructionof a brewing apparatus that is easy to use and requires minimalmaintenance. A review of the prior art described above demonstrates thateach different capsule version may meet one or more of the requirements,but not all of them.

What is needed is a capsule that meets all the market requirements, thatis easy and inexpensive to manufacture, is easy to use and enables theconstruction of brewing apparatus that meets all the market requirementsfor such apparatus and that requires minimal user maintenance.

SUMMARY

Therefore it is an object of this invention to provide a sealed capsulecontaining an infusible material that can be used in a beverage brewingapparatus that meets all the market requirements.

Another object of this invention is to provide a capsule containing aninfusible material that is inexpensive to produce, that preserves thefreshness of the infusible material and that is intuitively obvious touse.

Still another object of this invention is to provide a capsule for usein a beverage brewing apparatus that acts as a disposable infusionchamber and that isolates any brewed beverage from the brewingapparatus.

Yet another object of this invention is to provide a capsule that canaccommodate different quantities of infusible material.

Yet still another object of this invention is to provide a capsule forinfusible material that enables the construction of a beverage brewingapparatus that is easy to use and requires minimal maintenance.

In accordance with one aspect of this invention an infusible materialcapsule is provided for use in apparatus for dispensing a brewedbeverage into a beverage receptacle wherein the apparatus deliversliquid to the capsule and includes a capsule receiving station forsupporting said capsule. The capsule includes a capsule base thatcontains the infusible material. A dispensing structure directs brewedbeverage to the beverage receptacle. A standoff extends from the capsulebase proximate the dispensing structure for forming a seal support. Aseal attaches to the standoff for sealing the dispensing structure. Theseal ruptures against the dispensing structure as the capsule seats inthe capsule receiving station thereby to enable brewed beverage to passfrom the dispenser structure directly to the beverage receptacle.

In accordance with another aspect of this invention, an infusiblematerial capsule is provided for use in apparatus for dispensing abrewed beverage into a beverage receptacle wherein the apparatusdelivers liquid to the capsule. The capsule includes capsule base, coverand liquid distribution components. The capsule base component definesan open-ended cavity with a permeable support structure that containsinfusible material and from which brewed beverage can be dispensed. Thecover attaches to the capsule base and has a pierceable inlet fordirecting liquid into the cavity from the apparatus. The cover alsoseals the cavity. The liquid distribution component is intermediate thecover and the infusible material at a predetermined position in thecavity for distributing the liquid across the infusible material. Apositioner on the liquid distribution component maintains its positionin the cavity whereby the liquid distribution component can bepositioned to compress a range of infusible material quantities in thecavity.

In accordance with still another aspect of this invention, an infusiblematerial capsule is provided for use in apparatus for dispensing abrewed beverage into a beverage receptacle wherein the apparatusincludes a water delivery probe that delivers hot water under pressureto the capsule and a capsule receiving station. The capsule includes acapsule base having a side wall, an open end and a dispensing structureand having a floor and ribs that channel brewed beverage to thedispensing structure. The dispensing structure includes a sharpenedspout extending from the floor, a collar concentric with the spout, anda seal attached to the collar to overlie the spout to provide a firstseal for maintaining the freshness of the infusible material, the sealbeing ruptured over the sharpened spout as the capsule seats in thecapsule receiving station.

The capsule additionally includes a filter supported by the ribs,infusible material on the filter, a water distribution plate and acover. The water distribution plate has a plurality of aperturestherethrough and engages the side wall thereby to compact the infusiblematerial against the filter. The cover attaches to the capsule base atthe open end thereby to provide a second seal for maintaining thefreshness of the infusible material. A portion of the cover is adaptedfor being penetrated by the water delivery probe to deliver hot waterunder pressure intermediate the cover and the water distribution plate,

BRIEF DESCRIPTION OF THE DRAWINGS

The appended claims particularly point out and distinctly claim thesubject matter of this invention. The various objects, advantages andnovel features of this invention will be more fully apparent from areading of the following detailed description in conjunction with theaccompanying drawings in which like reference numerals refer to likeparts, and in which:

FIG. 1 is a perspective view of a capsule constructed in accordance withthis invention;

FIG. 2 is another perspective view of the capsule in FIG. 1 with aportion broken away;

FIG. 3 is a partially sectioned exploded view showing the components ofthe capsule in FIG. 1 in perspective;

FIG. 4 is a cross-sectional view taken along lines 4-4 in FIG. 1 of anassembled capsule containing a small amount of infusible material;

FIG. 5 is a cross-sectional view taken along lines 4-4 in FIG. 1 of anassembled capsule containing a maximum amount of infusible material;

FIG. 6 is a perspective view of a capsule base component for the capsuleof FIG. 1;

FIG. 7 is a cross-sectional view taken along lines 7-7 in FIG. 6;

FIG. 8 is a cross-sectional view of a water distribution plate used inthe capsule taken along lines 4-4 of FIG. 1;

FIG. 9 is a perspective view, partially broken away, of a covercomponent for the capsule of FIG. 1;

FIG. 10 is a cross-sectional view of the cover taken along the lines10-10 of FIG. 9;

FIG. 11 is a cross-sectional view of an alternate embodiment for acover;

FIG. 12 depicts a process for manufacturing capsules of this invention;

FIG. 13 is a perspective view of beverage brewing apparatus adapted toutilize a capsule constructed in accordance with this invention with itslid open;

FIG. 14 is a cross-sectional view through a portion of the apparatusshown in FIG. 13 with an open lid; and

FIG. 15 is a partial cross-sectional view like that in FIG. 14 with aclosed lid.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In the foregoing Description of Related Art, “capsule” and “cartridge”tend to be used interchangeably. The following description limits theterm to “capsule” for purposes of clarity and consistency.

Capsule 20

As shown in FIGS. 1 through 11, and particularly FIGS. 1 through 5, aninfusible material capsule 20 constructed in accordance with thisinvention is an integral structure comprising several components.Externally these include a capsule base 21 for containing the infusiblematerial and a capsule cover 22. Internally, the capsule 20 includes alayer of filter paper or filter 23 and a liquid or water distributionplate 24. Infusible material, such as the ground coffee 25 shown inFIGS. 4 and 5, is contained in a cavity intermediate the waterdistribution plate 24 and the filter 23 and bounded by a side wall 30 ofthe capsule base 21.

More specifically and referring to FIGS. 3 through 7, the capsule base21 includes a side wall 30 and has a cup shape with a closed bottom andan open top. A radially outwardly extending flange 31 on the side wall30 at the periphery of the open top provides a planar annular supportsurface for the cover 22. As shown in FIGS. 6 and 7, a floor 32 closesthe bottom of the capsule base 21 and is slightly concave in shape. Thefloor 32 includes a central dispensing structure 33 that directs thebrewed beverage through a central aperture 34 and a dispensing spout 35to a cup or other beverage receptacle. The dispensing spout 35 extendsexternally, downwardly in FIGS. 3 through 7, from the bottom floor 32 toa free end that is sharpened.

The floor 32 includes integral, radially extending, angularly spacedinterior ribs 36 and 37 that taper toward the periphery. The ribs 36 arelonger than the ribs 37. These ribs perform multiple functions. Theysupport the filter 23. In combination with the concavity of the floor32, the ribs 36 and 37 form converging, sloping channels from the sidewall 30 down to the aperture 34 thereby to channel brewed beveragethrough the aperture 34 and the dispensing spout 35. The ribs 36 and 37also maximize the rigidity of the floor 32 to maintain its structuralintegrity. In addition, the capsule 20 is formed with a circular ledge38 at the intersection of the side wall 30 and the floor 32 that furtherimproves capsule rigidity. During manufacture, the filter 23 is affixedto the ledge 38 in a manner known in the art to maintain the position ofthe filter 23 in the capsule base 21.

Referring specifically to FIGS. 2 through 5 and 7, a rim or collar 40extends downwardly from the exterior of the floor 32 thereby to form astandoff that is concentric with the spout 35 and proximate thereto.That is, the collar 40 extends for a distance that is at least thedistance the spout 35 extends from the floor 32. The collar 40 therebyprotects the dispensing spout 35 during handling and storage.

A free end 41 of the collar 40 forms an annular planar support surfacethat supports a thin gas impermeable sealing foil 42. The foil 42 sealsthe spout 35 to maintain the freshness of the infusible material 25. Thefoil 42 also prevents an individual from contacting the sharpened end ofthe spout 35. An adherent material, or other means, fixes the foil 42 tothe free end 41. In this embodiment, an outer peripheral cylindricalextension of the collar 40 forms a protective peripheral barrier orfence 43. The fence 43 prevents any accidental puncture of the foil 42by being pushed against the free end of the spout 35 prior to itsintentional puncture during the brewing process as will be discussedlater.

Now referring to FIGS. 3 through 5 and 8, the water distribution plate24 is a thin plate 44 with a dimpled center portion 45 and a peripheralpositioning structure 46. A plurality of spaced apertures 47 extendthrough the plate in an annular area 48 between the center portion 45and the positioning structure 46. Each aperture 47 allows the passage ofbrewing liquid, such as water, but blocks the passage of coffee grounds.The collective or total area for the apertures 47 allows the passage ofthe volume of liquid being supplied under pressure above the waterdistribution plate 24 with only a minimum pressure drop. The pluralityof apertures 47 can be in a random or ordered array.

The positioning structure 46 in FIGS. 4 and 5 enables the capsule 20 tobe manufactured with different quantities of infusible material.Specifically, the positioning structure 46 has a generally J-shape witha downwardly extending leg 50, a reverse bend 51 and a tail 52 with apreferably feathered outer surface 53 that slides over the interiorsurface of the side wall 30 as the water distribution plate 24 isinserted into the capsule 21.

As described in more detail later, the manufacturing process includesthe step of dispensing a quantity of infusible material, such as coffeegrounds, into the capsule 20. Referring to FIGS. 4 and 5, the capsulebase 21 with an installed filter 23 receives the infusible material.Then the water distribution plate 24 is inserted and displaced towardthe bottom wall 32 until a predetermined force has been achieved. Thisis the force required to compact the infusible material to a specifieddensity.

When that force is released, the positioning structure 46 blocks anyreverse displacement. Specifically, the resulting force on the waterdistribution plate 24 produces a radially outwardly acting force on thetail 52 that forces the feathered outer surface 53 against the interiorsurface of the side wall 30.

As will be appreciated, when the capsule base 21 is manufactured byinjection molding, the side wall 30 will not be cylindrical, but willhave a slight inward taper, or “draft” from the open end to the bottomwall 32. This “draft” enables the injection molding dies to separateafter a part is formed and the part to be ejected from the mold. Asknown, these draft angles are only a few degrees. When the draft angleis approximately 2° or less, the resulting frictional force between thefeathered outer surface 53 and the side wall 30 is greater than theforce trying to displace the water distribution plate 24, so the waterdistribution plate 24 remains fixed in position.

Thus, this positioning structure 46 is not dependent upon being lockedat a mechanically predetermined position within the capsule base 21.Consequently, the positioning structure 46 enables a capsule base 21 tohave sufficient depth to accommodate a range of quantities of infusiblematerials. In one embodiment, the capsule base 21 can accommodate up to18 grams (0.6 ounces) of coffee. FIGS. 4 and 5 depict differentconfigurations of a single version of a capsule with approximately 9grams and 18 grams of ground coffee respectively. Thus, the singlecapsule 20 is flexible because it can provide appropriate quantities ofinfusible material for cups of different sizes or for differentstrengths of the infusible material, including, but not limited to,coffee tea and cocoa, or for a combination of size and strength thereof.

In this embodiment the feathered outer surface 53 slides along a smoothinner surface of the side wall 30. It will be apparent to those skilledin the art that other mechanisms to limit a water distribution plate toa one-way motion can be substituted for the specifically disclosedpositioning structure 46. For example, a plurality of ridges could belocated over portions of the inner side wall surface to provide apositive incremental detent action by interacting with a structureequivalent to the tail 52.

Now referring to FIGS. 3 through 5, 9 and 10, the cover 22 has adome-like thin circular body 54 with a plurality of angularly spaced,radially extending, tapered ribs 55 extending from a central structure56 to a peripheral flange 57. The ribs 55 provide structural integrity.As previously indicated, the peripheral flange 57 and the flange 31 onthe base 21 are joined to form an integral assembly by ultrasonicwelding or other techniques.

The central structure 56 enables a water supply probe to pierce thecover 22 to deliver liquid under pressure to the capsule 20. The centralstructure 56 includes a cylindrical body 60 that depends from the body54 and terminates with a plurality of radially facing, arched passages61. A breakout 62 of the cover 22 is aligned with the cylindrical body60 to facilitate piercing. In this embodiment an integral cylindricalbarrier 63 surrounds the breakout 62 to block any propagation of theeffects of piercing thereby to preclude any impact on the integrity ofthe cover 22.

FIG. 11 depicts an alternative embodiment of the cover 22 wherein likereference numbers identify like elements. In this embodiment, like theembodiment of FIGS. 9 and 10, the central structure 56 includes acylindrical body 60 that depends from the body 54 and terminates with aplurality of radially facing, arched passages 61. In this embodiment,however, the breakout 62 and barrier 63 of FIGS. 9 and 10 is replaced bya preformed aperture 64 and a gas impermeable sealing foil 65. Thesealing foil 65 is fixed to a portion of the body 54 surrounding theaperture 64 to provide necessary sealing to maintain the freshness ofthe contents. The aperture 64 is sized to receive the probe. With thisalternative there is no requirement for breaking any of the material ofthe body 54 as shown in FIGS. 9 and 10. Rather the probe merelypenetrates the sealing foil 65 to access the interior of the capsule 20.This modification permits the foil to be printed with informationpertinent to the use of the capsule or to provide information about thecontent of the capsule.

Capsule Manufacture

Before describing the operation and use of the capsule 20 in FIG. 1, itwill be helpful to review the manufacturing process for the capsule 20.As will become apparent, the foregoing construction greatly simplifiesthe manufacturing process. First, it is possible to manufacture each ofthe components shown in FIG. 3, namely the base 21, the cover 22, thefilter 23, and water distribution plate 24 and the foil 42 in advance.With the proper selection of the depth of the base 21, only one version,or only a limited number of versions, will be required for thiscomponent to cover a wide range of content capacity. All the othercomponents will be identical notwithstanding the quantity of infusiblematerial to be included in the capsule 20. Further, other than thefilter 23, and foil 42, all the other components can be manufactured byinjection molding or other inexpensive manufacturing processes. Filters23 and foil 42 can be punched or otherwise cut from sheets or the like.Consequently, there is only a minimal cost associated with themanufacture of the components.

FIG. 12 schematically illustrates a process for manufacturing capsules,such as the capsule 20 in FIGS. 1 through 5. The process begins atStation I by inverting the capsule base 21 as shown for the applicationof the foil 42 onto the collar 40.

During a transfer from Station I to Station II, the capsule base 21 isinverted to an upright position. Station II loads the filter 23 into thecapsule base 21 to lie atop the ribs 36 and 37 and be affixed to thecircular ledge 38 as shown in FIG. 6. At Station III a dispenser, shownschematically as a dispensing tube 70, deposits an allocated quantity ofinfusible material, such as coffee grounds 25 into the capsule base 21over the filter 23.

At Station IV other manufacturing apparatus advances the waterdistribution plate 24 into the capsule base 21 to an appropriateposition to achieve the desired packing density.

At Station V, other manufacturing apparatus attaches the cover 22 to thetop of the base 21 such that the flanges 31 and 57 are aligned for beingjoined by an ultrasonic welder 71 or other known apparatus to form thecompleted capsule 20 at Station VI. As will be apparent, an inert gas,such as argon or nitrogen may be introduced into the capsule 20 prior toinstalling the cover 22. The introduction of such a gas displaces anyair within the capsule 20 to assist in preserving freshness.

As will now be apparent, the capsule 20 constructed in accordance withthis invention and shown in FIGS. 1 through 5 is inexpensive to produce.It is sealed to preserve the freshness of the infusible material.Further, as best illustrated in FIGS. 4 and 5, the capsule 20 canreceive a range of quantities of infusible material. The adjustmentsnecessary to change the quantity of infusible material are operatingchanges that control the dispenser 70 and the force applied to the waterdistribution plate 24. No tooling changes are involved, as might be toaccommodate capsule bases of different depths. The dimpled center 45 ofthe water distribution plate 24 provides some additional capacity byallowing the balance of the water distribution plate 24 to have a finalposition above the central structure 56 such that the integrity of thedimpled center 45 is not compromised during the piercing operation.

Brewing Apparatus

The manner in which a capsule constructed in accordance with thisinvention, like the capsule 20 in FIG. 1, enables the construction ofbrewing apparatus that further meet the various objectives of thisinvention can be better understood by referring to FIGS. 13 through 15that disclose one embodiment of a brewing apparatus 100 that takesadvantage of the characteristics of the capsule 20. As particularlyshown in FIG. 13, the brewing apparatus 100 has a base structure 101with a platform 102 for receiving a mug, cup or other type of beveragereceptacle 103.

A vertical structure 104 rises from the base structure 101 and supportsan upper structure 105 that cantilevers over the platform 102 Thevertical structure 104 also carries a hinged lid 106 and houses theelectrically operated equipment for producing hot water under pressure.In this particular apparatus the user can pour a required quantity ofwater into a water filling station 107 that is exposed when the lid 106is open. The apparatus 100 also includes a power cord 110 and a switch111 to initiate and terminate operations. Finally, the upper structure105 also has a capsule receiver station 112.

When the lid 106 is open, a user inserts the capsule 20 into the capsulereceiver station 112. Referring specifically to FIG. 14, the capsulereceiver station 112 includes a cup-shaped receiver component 113 with acylindrical side wall 114 that forms a well 115 that closely fits thecapsule side wall 30. A floor 116 has a central opening 117 formed by anannular depending channel 120 with an inner frustoconical wall 121 thatforms an inverted funnel-like opening 122. At the top of thefrustoconical wall 121, which is also shown in FIG. 13, the opening 122has a diameter that is larger than the diameter of the spout 35. Theouter diameter at the base of the wall 121 is less than the innerdiameter of the collar 40. As shown in FIG. 14, when a user places acapsule 20 in the capsule receiver station 112, the upper surface of thefrusto conical wall 121 initially supports the capsule 20 at the foil42. So the capsule 20 remains sealed.

Next, and referring to FIGS. 14 and 15, the user closes the lid 106 anduses a latch 123 to fix the lid 106 in a latched position. As shown inFIG. 15, the lid 106 includes cover member 124. The cover member 124 hasa smooth inner surface and an annular peripheral clamping surface 125.The clamping surface 125 aligns with a free edge 126 of the sidewall 114for the capsule receiver member 113. The lid 106 also supports a waterdelivery probe 127 with a central body portion 130 and a seal, a flatannular seal 131 in this embodiment. The water delivery tube attaches toa hot water delivery tube 132 from a hot water delivery system thatdelivers hot water under pressure to the probe 127.

Still referring to FIG. 15, as the user closes and latches lid 106,several actions occur essentially simultaneously. For example, the waterdelivery probe 127 penetrates the cover 22 through the breakout 62 shownin FIG. 9) and the flat seal 131 seals the cover 22 to the cover member124.

As the cover member 124 exerts a downward force on the cover 22, thecapsule displaces downward into the cup-shaped receiver component 113.This causes the frustoconical wall 121 to rupture the foil 42 over thesharpened spout 35 and to expose the open spout 35 in the opening 122.This downward motion continues until the capsule base floor 32 seats onthe floor 116. The collar 40 then lies positioned in the annular channelmember 120.

As the lid 106 latches, the capsule 20 is firmly held inside the cavitydefined by the receiver member 113 and the clamping member 124, with thecenter of the cover 22 proximate the flat annular seal 131.

FIG. 15 depicts the water distribution plate 24 at its maximum height.Probe penetration is limited and terminates above the dimpled center 45.Thus with the lid 106 closed and latched, a closed path for liquidexists from the delivery tube 132, through the probe 127 and the capsule20 to the spout 35. Both the hot water and brewed beverage are confinedto the interior of the capsule 20. The brewed beverage does not contactany portion of the apparatus 100.

In use, once the lid 106 is latched in place, the user closes the switch111 to initiate operation whereupon the electrical equipment apparatusin the vertical structure 104 produces hot water under pressure at therequisite temperature. A delivery tube 132 and the probe 127 direct thehot water into a chamber defined between the cover 22 and the waterdistribution plate 24. In this upper plate position, the water flowsthrough the arched passages 61 particularly shown in FIGS. 9 and 10 tospread over the top of the water distribution plate. When the cavitybetween the cover 22 and water distribution plate 24 fills, the pressurestabilizes and the water is forced through the distribution plateapertures and coffee grounds to be dispensed through the floor 32 andspout 35 into the receptacle 103. The internal water pressure alsoprovides the sealing force between the cover 22 and the flat annularseal 131.

As will now be apparent, the probe 127 also does not contact either thebrewed beverage or the coffee grounds. Specifically, the waterdistribution plate 24 prevents coffee grounds from migrating into thecavity between the cover 22 and the water distribution plate 24. Asessentially all the pressure drop occurs across the coffee grounds,brewed beverage does not migrate above the water distribution plate 24.

A capsule incorporating the features of this invention enables theconstruction of a brewing apparatus, such as the brewing apparatus 100,which achieves many objectives of this invention. Using apparatus forbrewing coffee as an example, a user opens the lid, selects a capsuleand deposits it in the capsule receiver station, pours water into theapparatus at the water inlet station, closes the lid and turns on aswitch. When the coffee has been brewed, the user only has to remove thefilled beverage receptacle from the apparatus. There is no requirementfor further user intervention. As a result, the apparatus is easy touse. As the beverage is brewed within the capsule, no brewed beverage orinfusible material contacts any part of the brewing apparatus.Consequently the brewing apparatus requires minimal cleaning becausethere is no need to clean any portion of the capsule receiver station.

A capsule in accordance with this invention also allows a hotel or othercommercial establishment to provide its customers or employees with avariety of brewing options from a single brewing apparatus. For example,a hotel could provide apparatus in each room with a variety of capsulesof the same exterior dimensions with different types of infusiblematerial, such as Columbian coffee, decaffeinated coffee, tea, cocoaetc. For a given type of infusible material the hotel could also providea variety of capsules of the same exterior dimensions with differentquantities of infusible material for brewing different amounts orstrengths of the beverage. Consequently, the hotel could provide theuser with a variety of beverage choices. Such capsules constructed inaccordance with this disclosure, or variations thereof, could alsoenable the implementation of brewing apparatus with still otheradvantages.

This invention has been disclosed in terms of certain embodiments andvariations on those embodiments. It will be apparent that the foregoingmodifications and many other modifications can be made to the disclosedapparatus without departing from the invention. Therefore, it is theintent of the appended claims to cover all such variations andmodifications as come within the true spirit and scope of thisinvention.

1. A disposable infusible material capsule for use in apparatus fordispensing a brewed beverage into a beverage receptacle wherein theapparatus includes liquid delivery means for delivering liquid to saidinfusible material capsule and wherein said disposable infusiblematerial capsule comprises: A) capsule base means having a bottom, aside wall characterized by a conical shape at a draft angle and an opentop for defining a receiving cavity including a permeable supportstructure for containing a quantity of infusible material, the brewedbeverage being dispensed from said bottom of said capsule base means, B)cover means attached to said open top of said capsule base means forsealing said receiving cavity and including a pierceable inlet means fordirecting liquid from the liquid delivery means into said receivingcavity, and C) liquid distribution means in said capsule base meansreceiving cavity intermediate said cover means and the infusiblematerial at an adjustable predetermined position in said capsule basemeans receiving cavity for distributing the liquid across the infusiblematerial and for compressing the infusible material, said liquiddistribution means including flexible positioning means with aperipheral portion having a J-shape for engaging the interior surface ofsaid capsule base means side wall for maintaining the adjustablepredetermined position of said liquid distribution means in said capsulebase means receiving cavity whereby during capsule manufacture saidliquid distribution means is adapted to be displaced to a position insaid capsule base means receiving cavity corresponding to the amount ofand desired packing density of the infusible material within saidcapsule base means receiving cavity thereby to enable said infusiblematerial capsule to contain any of a range of quantities of infusiblematerial under a desired compression after capsule manufacture has beencompleted and whereby the engagement of said J-shaped peripheral portionwith the interior surface of said side wall blocks any reversedisplacement of said liquid distribution means.
 2. The infusiblematerial capsule as recited in claim 1 wherein said flexible meansJ-shaped peripheral portion terminates with a feathered edge surfacethat engages the interior surface of said capsule base means side wall.3. The infusible material capsule as recited in claim 2 wherein saidliquid distribution means includes a plurality of apertures therethroughfor enabling the passage of the liquid and for confining the infusiblematerial between said permeable support structure in said capsule basemeans and said liquid distribution means.
 4. The infusible materialcapsule as recited in claim 1 wherein said cover means additionallyincludes central structure means including a plurality of radialpassages for directing liquid over said liquid distribution means. 5.The infusible material capsule as recited in claim 4 wherein said covermeans includes a plurality of angularly spaced ribs extending radiallyfrom said central structure means.
 6. The infusible material capsule asrecited in claim 4 wherein said cover means includes a centrally locatedbreakout portion that is easily penetrated.
 7. The infusible materialcapsule as recited in claim 6 wherein said cover means additionallyincludes means for localizing the effects of piercing said breakoutportion.
 8. The infusible material capsule as recited in claim 4 whereinthe liquid delivery means includes a liquid delivery probe and whereinsaid cover means includes a central aperture therethrough sized toaccommodate the liquid delivery probe and a gas impermeable sealing foilattached to said cover proximate said central aperture and overlyingsaid central aperture.
 9. A single-serve infusible material capsule foruse in apparatus for dispensing a brewed beverage into a beveragereceptacle wherein the apparatus includes a means for delivering waterunder pressure to said infusible material capsule and wherein saidinfusible material capsule comprises: A) a capsule base having a bottom,a side wall characterized by a conical shape at a draft angle and anopen top formed as an open-ended receiving cavity including a permeablesupport structure for containing a quantity of infusible material, thebrewed beverage being dispensed from said bottom of said capsule base,B) a cover attached to said open top of said capsule base with apierceable inlet portion for directing water from the water deliverymeans into said receiving cavity, said cover sealing said receivingcavity open top, and C) a water distribution plate in said capsule basereceiving cavity intermediate said cover and the infusible material atan adjustable predetermined position in said capsule base receivingcavity for distributing the water across the infusible material andcompressing the infusible material, said water distribution plateincluding a flexible positioner with a peripheral portion having aJ-shape that engages the interior surface of said side wall of saidcapsule base to maintain the adjustable predetermined position of saidwater distribution plate in said capsule base receiving cavity wherebyduring capsule manufacture said water distribution plate is adapted tobe positioned at a location within said capsule base receiving cavitycorresponding to the amount of and desired packing density of theinfusible material within said capsule base receiving cavity thereby toenable said infusible material capsule to contain any of a range ofquantities of infusible material under desired compression after capsulemanufacture has been completed and wherein said J-shaped peripheralportion blocks any reverse displacement of said water distributionplate.
 10. The infusible material capsule as recited in claim 9 whereinsaid J-shaped peripheral portion terminates with a feathered edgesurface that engages the interior surface of said capsule base sidewall.
 11. The infusible material capsule as recited in claim 9 whereinsaid water distribution plate includes a plurality of aperturestherethrough for enabling the passage of the water and for confining theinfusible material between said permeable support structure in saidcapsule base and said water distribution plate.
 12. The infusiblematerial capsule as recited in claim 11 wherein the brewing apparatuswater delivery means includes a water delivery probe and said coverincludes a pierceable portion that receives the probe and wherein saidcover includes a central structure including radial passagestherethrough for directing the water from the water delivery probe oversaid water distribution plate.
 13. The infusible material capsule asrecited in claim 12 wherein said pierceable inlet portion includes abreakout portion in said cover and a surrounding structure that blocksthe propagation of any breakage beyond said central structure.
 14. Theinfusible material capsule as recited in claim 12 wherein pierceableinlet portion includes a central aperture through said cover forreceiving the water delivery probe and a gas impermeable foil sealattached to said cover and overlying said central aperture.
 15. Theinfusible material capsule as recited in claim 12 wherein said coverincludes a plurality of angularly spaced ribs extending radially fromsaid central structure.
 16. An infusible material capsule for use inapparatus for dispensing a brewed beverage directly into a user'sbeverage receptacle from which the user will consume the brewed beveragewherein the apparatus includes a capsule receiving station, lid meansfor being moved between open and closed positions and a water deliveryprobe attached to the lid means that delivers heated water underpressure to said infusible material capsule wherein said infusiblematerial capsule is inserted into the receiving station when the lidmeans is open and is formed as an integral and disposable structure andcomprises: A) a capsule base having a side wall with an interior surfacecharacterized by a conical shape at a draft angle, an open end, adispensing structure and a bottom solid floor and ribs that channelbrewed beverage to said dispensing structure, said dispensing structureincluding: i) an integral spout affixed to and extending externally fromsaid bottom solid floor for a first distance to a sharpened free end,and ii) an integral collar concentric with and proximate said integralspout affixed to and extending externally from said bottom solid floorfor a distance greater than the first distance to a planar supportsurface, B) a seal attached to said planar support surface of saidcollar to overlie said spout proximate thereto and to provide a firstseal for maintaining the freshness of infusible material in saidinfusible material capsule whereby closure of the lid means with saidinfusible material capsule in the capsule receiving station causes saidseal to be displaced to engage said sharpened free end of said spout andrupture after which brewed beverage in said infusible material capsuleis directed through said integral spout directly to the user's beveragereceptacle without contacting the apparatus, C) a filter supported bysaid ribs, D) infusible material on said filter, E) a water distributionplate adjustably located within said capsule base to engage saidinterior surface of said capsule base side wall and to compact saidinfusible material against said filter and having a plurality ofapertures therethrough, said water distribution plate having a flexibleJ-shaped peripheral structure that engages the interior surface of saidcapsule base side wall to allow displacement of said water distributionplate into said receiving cavity and to block any reverse displacementof said water distribution plate, whereby the water distribution plateis adapted to be located within the cavity of said infusible materialcapsule to accommodate different quantities of infusible material byadjusting the position of said water distribution plate, and F) a coveraffixed to said capsule base at said open end and providing a secondseal for maintaining the freshness of said infusible material and saidcover having a portion thereof for being penetrated by the waterdelivery probe when the lid means is closed to a depth that isintermediate said cover and said water distribution plate thereby toenable the delivery of water under pressure intermediate said cover andsaid water distribution plate.
 17. The infusible material capsule asrecited in claim 16 wherein said J-shaped flexible peripheral portionterminates with a feathered edge surface that engages said interiorsurface of said capsule base side wall.
 18. The infusible materialcapsule as recited in claim 16 wherein said cover includes a pierceableinlet for receiving the probe and wherein said cover includes a centralstructure including radial passages therethrough for directing the waterfrom the probe over the water distribution plate.
 19. The infusiblematerial capsule as recited in claim 18 wherein said pierceable inletincludes a breakout portion in said cover and a surrounding structurethat blocks the propagation of any breakage beyond said centralstructure.
 20. The infusible material capsule as recited in claim 18wherein pierceable inlet includes a central aperture through said coverfor receiving the probe and a gas impermeable foil seal attached to saidcover and overlying said central aperture.
 21. The infusible materialcapsule as recited in claim 18 wherein said cover includes a pluralityof angularly spaced ribs extending radially from said central structure.